TWI785088B - Anti-pilling fabric and its manufacturing method - Google Patents

Abstract

The present invention provides a knitted fabric and a method for producing the fabric, especially the knitted fabric, which suppresses fluffing and reduces the strength and hand feeling of the fabric including short fibers of thermoplastic synthetic fibers. An anti-fluffing fabric and its production method, the anti-fluffing fabric comprises short fibers of thermoplastic synthetic fibers, and is characterized in that on at least one side surface of the fabric, there are: melting balls at the ends of the short fibers and hairiness of the short fibers Polishing marks of the molten ball at the tip.

Description

Anti-pilling fabric and its manufacturing method

Field of the Invention The present invention relates to an anti-pilling fabric containing short fibers of thermoplastic synthetic fibers and a method for producing the same. More specifically, the present invention relates to an anti-fluff knitted fabric comprising machine-spun yarns containing long fibers and/or short fibers of thermoplastic synthetic fibers and a method for making the same.

Background of the Invention Natural fibers other than spun silk are staples that are cut into shorter lengths. For example, cotton has a length of about 20 to 35 mm and a thickness of about 20 μm, and wool (merino) has a length of about 7.5 to 120 mm and a thickness of about 13 to 28 μm. Therefore, natural fibers are made into machine-spun yarns (hereinafter also referred to as short-fiber twisted yarns) through the spinning process in which the fibers are arranged, twisted, and bundled by carding the staple fibers. Machine-spun yarn has the characteristics of hairiness everywhere, bulkiness, softness, and heat retention. On the other hand, synthetic fibers are usually made into filament yarns (filament) by spinning, for example, most fibers such as polyester or polyamide are made by melt spinning, and polyacrylonitrile fiber (acrylic fiber) It is made by wet spinning method. In addition, regenerated cellulose fibers such as rayon or cuprammonium rayon fibers, and semi-synthetic fibers such as acetate fibers can also be made into filament yarns. Synthetic fibers can also be used as staple fibers after being cut into filament yarns.

Although synthetic fibers are generally characterized by lightness and toughness (strong and not easy to break) compared with natural fibers such as cotton, hemp, silk, and wool, most natural fibers have a soft and unique feel, and are mainly suitable for use as clothing materials. raw material. Although in order to make synthetic fibers achieve the soft feel that natural fibers have, it is only necessary to weave knitted fabrics with synthetic fiber machine-spun yarns, but it is known that knitted fabrics made of synthetic fiber machine-spun yarns are prone to fluffing. Pilling refers to the phenomenon that the surface of the fabric is rubbed during wearing or washing, and hairiness appears on the surface of the fabric, and the hairiness is entangled with each other to form a small pill. Especially when synthetic fibers such as polyester or polyamide are contained in the fiber, because the fiber is tough and difficult to break, it is easy to generate fuzz. Although there is no problem as long as the fluff falls off, these synthetic fibers are stretched without breaking when pulled, so fluff is difficult to fall off once generated, and it affects the appearance of the knitted fabric and also promotes the deterioration of the knitted fabric. Therefore, when knitted fabrics produced by machine spinning of synthetic fibers are used for clothing or products that require repeated washing, measures to suppress the occurrence of lint (that is, anti-lint measures) are indispensable.

In the past, for example, in the preparatory steps before dyeing, especially in worsted fabrics such as cotton, hairiness often occurs on woven or knitted fabrics, and when there are many hairinesses, the surface of the dyed product becomes unclear. In addition, since it becomes a cause of fluffing, so-called "singing" is performed to eliminate hairs. This process uses a gas burner or an electric heater to carbonize the hairs to burn them off and smooth the fiber surface. For pre-dyeds, singeing is performed after weaving, but also on the yarn.

On the other hand, in textile products, as described below, the braided fabric is actively fluffed to generate hairiness. In terms of cotton products such as jeans, when the hairiness covers the surface of the fabric, it will produce a soft and plump feeling, and the color will look whiter and fuzzy, and it will become more stable and exude a sense of luxury, so it will fade after washing The way to create a little fluff, creating a worn feeling. In terms of wool fabrics, after weaving, the stiff gray cloth is wetted, tapped, kneaded, etc. to make it felted and fluffed to produce hairiness, and the fibers on the cloth surface are scraped off and cut off in order to further generate hairiness, and the fluffing is carried out to produce hairiness . At present, it is known that a card clothing roller with metal needles is used to scratch and scrape the surface of the cloth to produce hairiness, or the surface of the cloth is rubbed with the thorns of thistle fruit, which can obtain a fluffing effect that feels softer than that of the card clothing. Thistle fluff. In order to obtain a high-sensitivity fabric with a smooth and soft texture, moisture retention, and touch like natural cashmere wool or angora wool, card clothing is made of short-staple machine-spun knitted fabrics using synthetic fibers such as polyester or acrylic. Raised hair is made at a high density and has extremely long hairs called spun wool.

In addition, corundum processing (suede processing) is also known in which a base material is ground with a sandpaper called corundum paper so that fine and short hairiness appears. Although the number of sandpaper is different, sanding, which is famous as a raising process for polyester fabrics, is also a process of raising sand using sandpaper. It is a plurality of sandpaper rollers with different degrees of raising, which are vertically overlapped. Rotate at a low speed, and rub and fluff the fabric by passing it through the rollers.

Especially for wool fabrics or fabrics that have been raised, shearing is performed to remove hairiness on the surface of the cloth, and operations such as trimming the length of the hairiness or random cutting are performed to clearly show the fabric structure or color, or to adjust the appearance .

In the following patent document 1, a needle knitted fabric for shirts is disclosed, which is a needle knitted fabric made of polyester staple fiber with a denier of 1.0 to 2.5 denier and cotton fiber blended yarn, wherein the composition ratio of the cotton fiber in the blended yarn is 75 to 90%, the twist constant of the blended yarn is 3.0 to 4.5, singeing after needle knitting. Cited Document 1 states that when the composition ratio of cotton fibers is less than 75% (that is, the composition ratio of polyester staple fibers is greater than 25%), polyester staple fibers melt during singeing after needle knitting. And make feel hard, become dirty easily at the same time. In other words, if the singeing that is adopted as an anti-fluffing measure for natural fibers is adopted as an anti-fluffing measure for polyester synthetic fibers, the hairiness that causes fluffing will not be carbonized and fall off like natural fibers, and polyester The hairiness will produce molten balls at the tip, which will cause deterioration of the hand feeling such as drying and hardening of the fabric.

In the following patent document 2, a method of manufacturing animal fur-style cloth is disclosed. In the case of singeing synthetic fibers, in order to obtain a soft hand like cashmere wool, polyester fibers, polyamide After singeing the plush tip of the plush napped fabric made of synthetic fibers such as amine fiber and acrylic fiber to form a synthetic fiber fusion ball, the plush tip is treated with a solvent or hydrolysis agent of the synthetic fiber with a predetermined viscosity. The way of processing and heat treatment makes the tip of the plush become thinner. This is because the part formed by the molten ball is in an amorphous and non-aligned state, and the dissolution rate and hydrolysis rate are significantly increased when treated with a solvent or a hydrolyzing agent, which can greatly shorten the treatment time, and at the same time make the tip extremely sharp. However, treating synthetic fibers with solvents or hydrolyzing agents is currently only suitable for limited applications such as women's clothing because it reduces the strength of the material.

In the following patent document 3, an anti-fluffing fabric is disclosed, which uses machine-spun yarns containing synthetic fibers to reduce the hairiness of each fiber in the cross-section by using a specific spinning method for the warp and/or weft, without singeing And/or alkali-reduced denim, denim and other fabrics, in which after washing (JIS L0217 103 method) 10 times, the anti-pilling measured according to JIS L 1076 A method (ICI type testing machine, 5 hours) The grade is 3 or more. In Patent Document 3, it is disclosed that the following problems are encountered when machine spinning of synthetic fibers is used, and therefore the use of products containing synthetic fibers for machine spinning is not widespread, and the problem is that synthetic fibers need to be treated to prevent fuzzing. Singeing treatment, and it is necessary to carry out alkali reduction or mercerizing treatment, or high-cost steps such as shearing to remove the synthetic fiber molten balls caused by it; it will deteriorate the hand feel and fastness; if only singeing is performed, there will be melting on the surface of the fabric The ball will irritate the skin, and repeated wearing and washing will cause the molten ball to rub the surface of the fabric, which will easily cause hairiness, and then deteriorate the surface color and wearing feeling of the fabric; in the case of denim or denim, it must be subjected to high pressure for a long time Strong acid, alkali and other chemical treatment steps.

In the following Patent Document 4, a method for producing polyester staple fiber fabrics is disclosed, which is for staple fibers containing polyester single fibers with a single fiber fineness of 0.01 to 10 denier and a single fiber strength of 2.5 g/denier or more. The fabric is fluffed, and then the surface of the knitted fabric is beaten and rubbed on the surface of the support roller with a flexible rough surface material with a polished film surface, and the surface hairiness is processed to an average hairiness of at least 1.1 mm and less than 50 mm. , and the average hairiness density is above 200/cm. In addition, it is also disclosed that in such a beating and rubbing process, the long coarse hairs on the napped surface processed by the card clothing are forcibly pulled up and cut off with a flexible rough surface material with a polished film surface, and the pile loops are cut off and removed. Or knotted fibers, newly formed slightly shorter and denser hairs. Patent Document 4 also discloses that compared to the anti-fluffing grade measured in accordance with JIS L1076 after polishing wheel processing by emery rollers in the past, it is 1-2 grades, and the treatment method using the above-mentioned polishing film is 5, 4-5 grades. Patent Document 4 discloses that spun polyester spun yarns with high physical properties are being improved and commercialized, but since spun fabrics made of such spun short fibers have long hairiness, compared to Generally, the hairiness on the surface of short-haired combed fabrics will be rubbed by wearing or washing, and fluff will be generated quickly, which will significantly damage the quality and appearance of the fabric. This is because the short-fiber hairiness on the surface of the fabric is rubbed Kneading makes the hairiness existing on the surface or the hairiness pulled out from the fabric entangled with each other, and the entangled hairiness is not easy to fall off, which is a very serious problem for synthetic fibers such as polyester with high fiber strength and elongation. , As countermeasures against the defects called fluffy clusters such as fluffing or slight fluffing, there are known: (1) methods of reducing the strength and elongation of fibers; (2) improving the structural bonding force of fabrics (3) The method of embrittlement of surface hairiness; (4) The method of singeing; (5) The method of resin processing, etc., but any method has its advantages and disadvantages. It is extremely difficult to spin wool-style polyester staple fiber fabrics that are soft, soft, and feel good.

In Patent Document 4, it is disclosed that singeing is particularly suitable for short-haired carded knitted fabrics. This is a method of singeing the hairs on the surface of the cloth with a gas burner when dyeing the cloth, but it is not applicable. For spun wool with long hairiness, although it can be confirmed that it has a certain degree of anti-fluffing effect after application, the melt ball of hairiness will remain on the surface, so it will feel rough, the handle will become hard due to heat treatment, and the insulation will be lacking. issues such as sex. As described above, the technology disclosed in Patent Document 4 is to apply the anti-fluffing countermeasures of producing short and dense hairiness by using a specific polishing method to spun knitted fabrics using synthetic fiber machine-spun hairiness, instead of the prior art anti-fluffing measures. Countermeasures. Citation 4 reveals that because the general polishing wheel processing and roughening processing are ground by emery rollers or emery polishing belts, excellent anti-pilling effects cannot be obtained, so instead of this method, the flexible rough surface with a polishing film is rotated The material is processed by beating and rubbing the braid on the surface of the support roll, and the surface of the polishing film is a sharp feather-like laminated metal plate whose thickness decreases rapidly toward the tip. The key point of this special polishing treatment method is to use a sharp rough surface material to forcibly pull up and cut off the long thick hairs on the napping surface of the card clothing, and at the same time cut off and remove the piles or knotted fibers, and generate slightly shorter and denser fibers by new generation. hairiness to shape the surface. That is, by removing the outermost "shedding" and producing only "strong hair", abrasion resistance is improved and anti-pilling property is imparted.

In the following Patent Document 5, there is disclosed a method of producing a raised fabric, which is to run a fabric woven with sized warp yarns at a predetermined speed, and bring the fabric into contact with a ceramic roll composed of inorganic powder of particle size #100 to 800 , this method is not like thistle fluffing or card clothing fluffing which pulls out the fibers from the inside. This method can only fibrillate the surface to form a soft feel like peach skin, and can also improve the fluffing characteristics. For voile yarn Thin fabrics that do not produce rope-like wrinkles, scratch-like spots, and structural disturbances can also be fluffed, and the tear strength of the fabric will not decrease due to fluffing. In Patent Document 5, it is also disclosed that compared with polishing with emery paper (#200) in the past, polishing with a ceramic roll made of inorganic powder with a particle size of #100 to 800 will improve the feel and anti-pilling properties. In addition, because only The surface of the fiber is fibrillated to produce fine hairiness, so physical methods such as singeing or shearing after fluffing, or post-treatments such as chemical methods using chemicals are not required.

The following Patent Document 6 discloses a method of obtaining a modified synthetic fiber by blending a monomer that improves the fuzz resistance with the monomer constituting the synthetic fiber and copolymerizing it, and imparting fuzz resistance and high shrinkage (bulkyness) . However, available fiber materials are limited to polyester, which is accompanied by problems such as loss of original properties or feel of synthetic fibers, reduction in fiber strength, or increase in cost due to fiber modification.

As described above, although singeing is used in Cited Documents 1 and 2 as an anti-fuzzing countermeasure for a knitted fabric using synthetic fiber machine spinning, Cited Documents 3 to 6 instead disclose that singeing should not be used. In addition, as mentioned above, although it is disclosed in Cited Document 3 that the molten balls caused by singeing of synthetic fibers seem to be able to be removed by shearing, it is actually difficult to compare with the case of polishing because shearing is originally a method for cutting napped fibers. The same applies to non-fluffed products, but even if it is applied, there is a very high risk of damaging the fabric material, so it is not actually used. In addition, although specific polishing methods are disclosed in Cited Documents 4 and 5, these polishing methods are techniques applicable to raised products. In the case of synthetic fiber machine spinning, it is difficult to treat only the hairiness that causes fluffing without damaging the raw material fabric because hard hairiness (hairlines) will be avoided even if it is polished. As such, methods such as singeing, reduction of fiber strength, buffing, shearing (shearing processing, trimming), fiber material modification, etc. The anti-pilling measures for spun knitted fabrics are not sufficient, so there is a tendency to exclude the option of using synthetic fiber machine spinning in the review stage of clothing product development. Furthermore, surprisingly, a processing step combining singeing and polishing as an anti-fuzzing countermeasure for machine-spun knitted fabrics using synthetic fibers is not known and has not been practiced so far. Prior Art Documents Patent Documents

Patent Document 1: Japanese Patent Application Publication No. 8-144158 Patent Document 2: Japanese Patent Application Publication No. 61-31234 Patent Document 3: Japanese Patent Application Publication No. 2004-197243 Patent Document 4: Japanese Patent Application Publication No. 9-95859 Publication No. Patent Document 5: Japanese Patent Laid-Open No. 7-97764 Patent Document 6: Japanese Patent Laid-Open No. 2016-108702

Summary of the Invention Problems to be Solved by the Invention In view of the current state of the art above, the problem to be solved by the present invention is to provide a knitted fabric and a manufacturing method thereof. Fluffiness is suppressed, and the reduction in the strength of the fabric and the deterioration of the hand feeling are suppressed. means to solve problems

As a result of continuous research and experiments by the present inventors in order to solve the above-mentioned problems, the inventor unexpectedly found the following fact: using short fiber machine-spun yarns containing thermoplastic synthetic fibers as raw yarns for weaving or knitting to obtain knitted fabrics with hairiness of the short fibers , and performing singeing on at least one side surface of the woven fabric to form molten balls at the ends of the staple fibers, and then polishing the formed staple fiber hairiness by using, for example, a roller polisher or a belt sander The molten balls at the tip are rubbed to form polishing marks, thereby obtaining a knitted fabric which is extremely excellent in fuzz resistance and suppresses reduction in cloth strength or deterioration of hand feeling due to manufacturing stages or repeated use, thus completing the present invention.

That is, the content of the present invention is as follows. [1] An anti-pilling fabric, comprising short fibers of thermoplastic synthetic fibers, characterized in that on at least one surface of the fabric, there are: molten balls at the ends of the short fibers, and polishing of the molten balls at the tip of the hairiness of the short fibers mark. [2] The anti-fluffing fabric described in [1] above, wherein the thermoplastic synthetic fiber is selected from the group consisting of polyesters, polyamides, polyacrylics, polyvinyl chlorides, and polyvinylidene chlorides. , polyvinyl alcohol, polyolefin and polyurethane fibers in the group. [3] The anti-pilling fabric described in [1] or [2] above, which is a knitted fabric. [4] The anti-pilling fabric described in [3] above, after washing 10 times and 30 times according to JIS L 1930 C4M method (using drum type), followed by JIS L 1076 A method (using ICI type testing machine) Method) The measured anti-pilling grades are all above grade 3. [5] A method for producing a fuzz-resistant fabric, comprising the steps of: machine spinning, weaving or knitting, or fabric manufacturing using long fiber threads and/or short fibers comprising thermoplastic synthetic fibers as precursors, The cloth has the hairiness at the cut end of the long fiber thread or the hairiness of the short fiber; singeing at least one side surface of the obtained cloth to form a molten ball at the cut end of the long fiber thread or the end of the short fiber; and by Polishing is a step of rubbing the molten balls formed at the truncated end of the long fiber thread or the tip of the hairiness of the short fiber formed on one side surface of the obtained cloth to form polishing marks. [6] The method described in [5] above, wherein the thermoplastic synthetic fiber is selected from polyesters, polyamides, polyacrylics, polyvinyl chlorides, polyvinylidene chlorides, polyethylene Fibers in the group consisting of alcohols, polyolefins and polyurethanes. [7] The method described in [5] or [6] above, wherein the anti-pilling fabric is a knitted fabric. [8] The method described in [7] above, wherein the anti-fluffing fabric is washed 10 times and 30 times according to the JIS L 1930 C4M method (using the drum type), and then according to the JIS L 1076 A method (using the ICI type test method). The anti-pilling grades measured by machine method are all above grade 3. Invention effect

The fuzz-resistant fabric containing short fibers of thermoplastic synthetic fibers related to the present invention is, for example, a woven fabric, because molten balls produced by singeing process remain inside the cloth, and only melted balls at the tip of hairiness of short fibers exist on the surface of the cloth. Polishing marks, so the anti-pilling property is extremely excellent, and can suppress significant strength reduction or hand feeling deterioration even at the manufacturing stage or after repeated use. Therefore, the present invention can apply the woven fabrics spun by synthetic fibers, which have been difficult to put into practical use, to various clothes or other fiber products with desired hand feeling or appearance. As long as the kind of synthetic fiber used as the raw yarn is thermoplastic, it can be freely selected without any limitation. In addition, the present invention can also be applied to raised knitted fabrics and the like. Furthermore, it can also be applied to the knitted fabric which has the fiber which cut|disconnected the said long fiber in the process of weaving, knitting, etc. on the surface of the long-fiber knitted fabric. Therefore, the anti-pilling fabric containing short fibers of thermoplastic synthetic fibers related to the present invention can also be applied, for example, to provide clothes that have a soft feel like natural fibers, and are lighter and more durable than natural fibers, or are durable even after repeated use. Various fiber products such as deteriorated sheets and bedding covers.

Embodiments for Carrying Out the Invention Hereinafter, embodiments of the present invention will be described in detail. One embodiment of the present invention is an anti-pilling fabric, comprising short fibers of thermoplastic synthetic fibers, characterized in that on at least one side surface of the fabric, there are: molten balls at the ends of the short fibers, and fluffy tips of the short fibers Polishing traces of molten balls.

In this specification, the term "thermoplastic synthetic fiber" is not particularly limited as long as it is formed into molten balls by gas singeing fusion, and chemical fibers composed of chemically synthesized polymers, such as polyesters, can be mentioned. , polyamide, polyacrylic, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyolefin, polyurethane and other synthetic fibers. For example, the melting point of polyester staple fibers is 255 to 260°C, the melting point of nylon staple fibers belonging to polyamide fibers is 215°C to 220°C, and the melting point of polyacrylic fibers is not clear, but the softening point is 190°C. The melting point of polypropylene staple fibers belonging to polyolefin fibers is 165 to 173°C to 240°C. On the contrary, cotton (cotton cotton), which is a natural fiber, decomposes at 235°C and burns at 275 to 456°C, while wool (merino) thermally decomposes at 130°C, burns at 205°C, and carbonizes at 300°C. In addition, rayon or copper ammonium rayon fibers, which are regenerated cellulose fibers, will not soften or melt, and will start to color and decompose at 160°C to 300°C. The thermoplastic synthetic fibers in this embodiment are preferably selected from polyesters, polyamides, polyacrylics, polyvinyl chlorides, polyvinylidene chlorides, polyvinyl alcohols, polyolefins, and The fibers of the polyurethane group are preferably polyester, polyamide or polyacrylic fibers.

In this specification, the term "short fiber" refers to staple fibers (staples) that are cut into short lengths, and in the case of staple fibers of thermoplastic synthetic fibers, are generally those that will be made into long fibers (filament yarns). Fiber cut off. From the viewpoint of textile processability, the length of the short fibers is preferably 20 to 70 mm, more preferably 30 to 60 mm, more preferably 38 to 51 mm. From the standpoint of spinnability and maintenance of fabric strength, the fineness (single fiber fineness) of the short fibers is preferably 0.01 to 10 deniers, more preferably 0.8 to 5 deniers, more preferably 1.0 to 2.5 deniers. If the single fiber fineness is less than 0.01 denier, it is easy to get dirty, and the tips of the generated hairiness are easy to gather to form fluff. Once the lint formed becomes difficult to fall off, the hand feel will also deteriorate. The cross section of the short fiber can be a circular cross section or an irregular cross section. In addition, in this specification, the term "short fiber" also includes fibers having cut ends, which use long fibers of thermoplastic synthetic fibers as precursors and obtain gray fabrics by weaving, needle knitting, etc., in which gray fabrics The surface is produced as a result of the long fibers being cut by weaving, needle knitting, raising, etc.

In this specification, the term "machine spun yarn (short fiber twisted yarn)" refers to a yarn in which the fibers are arranged, twisted, and bundled by unraveling and carding the short fibers. From the viewpoint of forming molten balls, the machine-spun yarn is preferably composed of short fibers of only one thermoplastic synthetic fiber, but may also be a blended yarn of short fibers of two or more thermoplastic synthetic fibers. In addition, it can also be a blended yarn of short fibers of thermoplastic synthetic fibers and other natural fibers, or it can be twisted yarns or worsted ply yarns of conjugated fiber yarns and filament yarns. The yarn count of the machine-spun yarn is preferably 7 to 120 (760 to 44 denier). If it is less than 7, it is a thick fabric, and if it is more than 120, the toughness will decrease. In addition, the twist is preferably 60 to 1500 times/m.

In this specification, the term "fabric" may be any of woven fabric, knitted fabric (circular knitted fabric, warp knitted fabric, weft knitted fabric), and non-woven fabric. From the viewpoint of exerting desired effects as clothing products, the cloth is preferably woven or knitted. The woven fabric is preferably composed of 100% machine-spun yarn, but a blended fabric using long fibers for the warp and machine-spun yarn for the weft is also suitable because it can obtain a soft and elastic feel. The woven fabric structure and the knitted fabric structure are not particularly limited. Furthermore, in this specification, the term "knitted fabric" refers to a woven fabric or a knitted fabric.

In this specification, the term "hairiness" refers to the ends of short fibers that stand up from the surface of the fabric, and the ends of short fibers that exist inside the fabric or inside the machine-spun yarns that make up the fabric are not called hairiness. Figures 1 and 2 show examples of polyester hairiness, and Figure 7 shows an example of nylon hairiness.

In this specification, the term "fused ball" refers to melting the hairiness of the thermoplastic synthetic fiber by singeing and deforming it into a roughly spherical shape. In this embodiment, molten balls present on the surface of the cloth are converted into polishing marks by rubbing by polishing. Fig. 5 shows an example of a polyester fusing ball, and Fig. 9 shows an example of a nylon fusing ball.

In this specification, the term "polishing marks" refers to short fiber ends having a shape in which molten balls on the surface of the cloth have marks scratched by polishing. Figures 3, 4, and 6 show examples of polishing marks of polyester, and Figure 8 shows examples of polishing marks of nylon.

Another embodiment of the present invention is a method for producing a fuzz-resistant fabric, comprising the steps of: machine-spinning, weaving or needle-knitting a fabric having hairiness of the short fiber using short fibers containing thermoplastic synthetic fibers as raw yarns singeing at least one side surface of the resulting braid to form molten balls at the ends of the short fibers; The step of forming polish marks. Hereinafter, an example of manufacturing the fuzz-resistant fabric of this embodiment will be described. The staple fibers of thermoplastic synthetic fibers are made into machine-spun yarns. In this case, it may be a blended yarn of two or more thermoplastic synthetic fibers, or may be a blended yarn of one or more thermoplastic synthetic fibers and one or more natural fibers. Then, machine-spun yarns are used as warp and/or weft to weave gray fabric. Next, the gray cloth is desized and refined.

Next, the following singeing is performed. (Singeing) Make the tip of the hairiness existing on the surface of the fabric form a molten ball. At this time, molten balls may be buried inside the fabric or appear at the ends of the short fibers outside the machine-spun yarn. However, since the molten balls existing in these parts will not appear on the surface of the fabric, there is no need to worry about causing damage. The feel of the fabric deteriorates. Singeing can be performed, for example, by direct singeing (gas singeing) using a flame from a gas burner and/or indirect singeing (contact singeing) by contact with a heating roll. Since the melting point of polyester and nylon is 210 to 260°C, it is suitable for direct singeing. For materials with a higher melting point, it is advisable to perform indirect singeing that makes the temperature of the heating roller high and transfers heat in a short time. The singeing conditions are not particularly limited, as long as the tips of the feathers existing on the surface of the fabric and causing fluffing can be formed into molten balls. The passing speed of the fabric fed to the singeing step (singeing processing speed) is preferably 60 to 120 m/min, more preferably 80 to 100 m/min. In addition, when the machine-spun yarn contains natural fibers, it is preferable to perform gas singeing because fuzzing can be suppressed only by burning all the hairiness of the natural fibers to carbonization by gas singeing.

Next, the following polishing is performed. (Polishing) By the above-mentioned singeing, the molten balls at the tips of short fiber hairs formed on at least one side surface of the woven fabric are scraped by polishing using, for example, a polishing agent or sandpaper, thereby forming polishing marks. In the case where molten balls are formed on both sides of the cloth, polishing should also be performed on both sides. The polishing method can be carried out by hand, and various polishing machines can also be used. As the polishing machine, there may be used a roll polisher which applies a polishing agent to a roll, a roll polisher which rolls a polishing paper to a roll, and a belt sander which uses a belt-shaped polishing paper. Fig. 10 shows an example of a polishing device using a belt sander. In the case of using a belt sander to polish both sides of the cloth, it is only necessary to replace the polished side and perform two polishings. As shown in Figure 10, the fabric after singeing is preheated by the heating cylinders (3 to 5) through the reverse rollers (1, 2), and passed through the reverse rollers (6 to 8), by means of the movable pressing valve (9), While being pressed to the rotating abrasive belt (10) while adjusting the pressing intensity, the molten balls on the surface of the cloth are rubbed to form polishing marks. The powder produced by polishing is removed by the paper powder remover (11) and blank powder remover (12, 14), and finally the cloth from which the polishing powder has been removed is folded and recycled by the shake-off device (19).

Conventionally, the anti-fuzzing countermeasures by polishing are fibrillation as described in Patent Document 5, but the polishing in this embodiment is performed to scrape off molten balls generated by singeing. As shown in Fig. 5 and Fig. 9, since the molten ball presents a nearly spherical shape with a predetermined size, when the polishing agent or polishing paper is brought into contact with the surface of the cloth for wiping, the molten ball is preferentially polished and rubbed because it cannot enter the interior of the cloth. Including, the damage to the base tissue of the fabric is suppressed to a minimum. Therefore, by such polishing, the biggest problem of thermoplastic synthetic fiber singeing can be eliminated, that is, the molten balls will remain on the cloth to cause roughness of the cloth, and the deterioration of the handle or appearance can also prevent the strength of the cloth from decreasing. Although special polishing methods are taught in Citations 4 and 5 as described above, these polishing methods are technologies suitable for raised products, and synthetic fiber machine spinning has hard hairiness (hair tips) even if it is polished. Avoid, so it is difficult to deal with only the hairiness that causes fuzziness without damaging the raw material fabric. However, the present inventors have found the following fact: If the hairiness with molten balls formed at the tip portion by singeing becomes difficult to avoid, it can be polished by rubbing without damaging the raw material cloth. Melted balls can be used to manufacture fabrics with excellent fuzz resistance, thus completing the present invention. In addition, as mentioned above, although it is stated in Citation 3 that molten balls caused by singeing of synthetic fibers seem to be able to be removed by shearing, since shearing is originally a method for cutting fluffed fibers, it should be applied as in the case of polishing. Other than napping products, it is actually very difficult, and even if it is applied, there is a very high risk of damaging the fabric material, so it is not actually used.

(Fluffing treatment) The method for producing the fuzz-resistant fabric of this embodiment can also be applied to knitted fabrics and the like having a raised surface. A method in which a raw material is produced by weaving or knitting by machine spinning short fibers containing thermoplastic synthetic fibers as raw yarns, and making the surface of the raw material into a fluffed state, such as processing such as card clothing fluffing treatment, emery fluffing treatment, etc. Method; method by weaving like pile fabric; method of knitting like fabric by center cutting of double-face raschel knitted fabric. Singeing is performed on at least one side surface of a braided fabric etc. having a napped surface, forming molten balls at the ends of the short fibers, and making the hairiness of the short fibers formed on the one side surface of the obtained braided fabric etc. tipped by polishing The part of the molten ball is rubbed to form a polishing mark. In addition, the manufacturing method of the anti-fluffing fabric of this embodiment can also be applied to the following knitted fabrics, that is, the surface of gray fabrics obtained by weaving, knitting, etc., using long fibers of thermoplastic synthetic fibers as raw yarns. Long fibers are cut off by weaving, needle knitting, fluffing, etc., resulting in the existence of short fibers. This is because as long as there are fiber ends on one side surface of the blank, molten balls can be formed at the fiber ends by singeing, and by melting the balls at the tip of the hairiness formed on the one side surface of the braided fabric obtained. Polishing is carried out so that it is rubbed and formed polishing marks to exert the desired effect.

(Heat Setting) Next, heat treatment is performed to eliminate the influence of uneven heat history of synthetic fibers. Heat setting is preferred for fabric dimensional stability or even dyeing. In the case of polyester fibers or nylon fibers, the heat treatment is performed at 180° C. for about 30 seconds to 1 minute.

(Dyeing) The dyeing is not particularly limited. Dyeing includes exhaust dyeing (kneading) and continuous dyeing, and exhaust dyeing is more common. Although continuous dyeing is used for some polyester series, it will harden the hand and damage the softness. In terms of exhaust dyeing, if singeing is performed before dyeing, dye spots will occur due to the difference in dyeability between the molten ball and the base material, but in this embodiment, since the molten ball on the surface of the cloth is removed by polishing, it will not There is a problem of staining. If the singeing is uneven, stripes and stains will occur. In the case that the stripe dyeing spots cannot be solved by singeing anyway, the fabric can also be singed and polished after the yarn is dyed, that is, it can be dyed before singeing or dyed after singeing. (Complete drying) Then dry and finish.

Since the braided fabric with the anti-pilling countermeasures implemented by the above manufacturing method has undergone the singeing step and the polishing step, as shown in Fig. 3, Fig. 4, Fig. 6, and Fig. 8, when inspected with an electron microscope, it is confirmed that there is buried The molten ball at the end of the short fiber inside the fabric but outside the machine-spun yarn is rubbed against the molten ball at the tip of the hairiness on the surface of the fabric, resulting in polishing marks. By carrying out the anti-pilling countermeasures including the singeing step and the polishing step described above, even a woven fabric containing short fibers of thermoplastic synthetic fibers and having an anti-fluffing grade of 1 to 2 can be made to achieve a fuzzing-resistant grade of It is grade 3 or higher, preferably grade 4 or higher, more preferably grade 5, and also can be made into a woven fabric that suppresses reduction in strength or deterioration of texture. The knitted fabric to which the anti-fluffing measure of this embodiment is implemented is, as shown in the following examples, the fluffing performance is sustainable even under repeated washing, and the durability is also excellent in this point of view. (Example)

[Example 1] Manufacture of spun polyester product (singeing+polished product) Carry out staple polyester fiber (short fiber of polyester fiber, 1.6 denier, 38mm cut) by machine spinning according to a conventional method to obtain polyester Ester machine spinning (30 counts). Warp the obtained polyester machine-spun yarn into a warp, use POVAL as the main warp size to sizing the warped warp, and then use the polyester machine-spun yarn obtained in the same way as a weft, and shuttle Weave into the plain weave gray cloth of warp thread density 90/inch (2.54cm), weft thread density 70/inch. After desizing and scouring the gray cloth obtained, both sides of the cloth were singed with a gas burner (80 m/min) to form molten balls on the cloth. Next, both sides of the cloth were polished with an abrasive belt (mesh #1000) to remove molten balls generated on the surface of the cloth. Afterwards, a plain weave test cloth made of staple polyester fibers was obtained through a step of heat setting at 180° C. for 1 minute, a kneading step by exhaust dyeing, and a drying step.

[Comparative Example 1] Manufacture of staple fiber polyester product (conventional processed product), a test cloth was obtained in the same manner as in Example 1 except that the singeing step and the polishing step were omitted.

[Comparative Example 2] Manufacture of staple fiber polyester product (singeing + weight reduction processed product), except that after the singeing step of Example 1, alkali weight reduction treatment (10%) was carried out instead of the polishing step, in the same manner as in Example 1 The experimental cloth was obtained in the same way.

[Comparative Example 3] Manufacture of staple fiber polyester product (singeing + weight reduction processed product) except that after the singeing step of Example 1, alkali weight reduction treatment (20%) was carried out instead of the polishing step, in the same manner as in Example 1 The experimental cloth was obtained in the same way.

[Comparative Example 4] Manufacture of staple fiber polyester product (singeing+weight reduction processed product), except that after the singeing step of Example 1, alkali weight reduction treatment (30%) was carried out instead of the polishing step, in the same manner as in Example 1 The experimental cloth was obtained in the same way.

[Example 2] Manufacture of staple polyester products (singeing+weight reduction processed products) Carry out machine spinning of 1.7 denier, 38mm cut staple nylon fibers (short fibers of nylon 66 fibers) according to conventional methods to obtain nylon machine Spinning (30 counts). The obtained nylon machine-spun yarn is warped into a warp, and the warped warp is sized with POVAL as the main warp, and then the nylon machine-spun yarn obtained in the same way is used as a weft, and woven into Plain weave gray fabric with a warp density of 90 threads/inch and a weft thread density of 70 threads/inch. After desizing and scouring the gray cloth obtained, both sides of the cloth were singed with a gas burner (80 m/min) to form molten balls on the cloth. Next, both sides of the cloth were polished with an abrasive belt (mesh #1000) to remove molten balls generated on the surface of the cloth. Afterwards, a test cloth made of spun nylon fibers was obtained through a heat-setting step at 180° C. for 1 minute, a kneading step by exhaust dyeing, and a drying step.

[Comparative Example 5] Manufacture of spun nylon product (conventional processed product), a test cloth was obtained in the same manner as in Example 2 except that the singeing step and the polishing step were omitted.

[Example 3] Manufacture of blended raised material product (singeing+polished product) is prepared to use twisted yarn (final blending ratio 61:33:6) as the colored spinning cloth (96 through 96) woven as warp and weft. root × weft 90), the twisted yarn is a blended yarn (40 counts) made of two polyester fibers (38mm cut, top dyed) and rayon fibers (38mm cut) at a blending ratio of 65:35 ), and one polyurethane filament yarn (40 denier). The cloth is prepared and then further card-fluffed. The cloth was gas-singed (80 m/min) to form molten balls. Next, both sides of the cloth were polished with an abrasive belt (mesh #1000) to remove molten balls generated on the surface of the cloth. Afterwards, a plain weave test cloth made of blended materials was obtained through a heat setting step at 180° C. for 1 minute.

[Comparative Example 6] Manufacture of blended raised material product (singeing processed product), a test cloth was obtained in the same manner as in Example 3 except that the polishing step was omitted.

[Comparative Example 7] Manufacture of blended raised material product (conventional processed product), a test cloth was obtained in the same manner as in Example 3 except that the singeing step and the polishing step were omitted.

Using the experimental fabrics obtained in Examples 1 to 3 and Comparative Examples 1 to 7, the anti-pilling test and the tear strength test were performed on samples that were not washed, washed 10 times, and washed 30 times. However, the tear strength test was omitted for the experimental cloths obtained in Example 2, Comparative Example 5, and Example 3, and the test cloths obtained in Comparative Examples 6 and 7 were also omitted after washing 10 times and 30 times. Anti-pilling test. The results are shown in Table 1 below. The fuzz resistance test was carried out for 10 hours in accordance with JIS L 1076 A method (method using an ICI type testing machine). The test result is an average value of the judgment results of four test pieces. The tear strength test was performed in accordance with JIS L 1096D (pendulum method). Washing was performed 10 times and 30 times according to the JIS L 1930 C4M method (using a drum type).

[Table 1]

As can be seen from Table 1, the experimental fabrics of Examples 1 to 3 have been singed and polished, and their anti-pilling grades are still the highest grade 5 even after washing 30 times. It is also good, and the strength is not reduced. On the other hand, the anti-pilling grade of the experimental cloth of Comparative Example 1 that has not been singed and polished during the manufacturing process is 1, the experimental cloth of Comparative Example 5 is 1.5, and the experimental cloth of Comparative Example 7 is grade 1. The anti-pilling grade of the experimental cloth was grade 1, and many fluffs were generated during the manufacturing stage. In addition, alkali weight reduction treatment is conventionally regarded as a countermeasure against fluffing of staple polyester fibers. In Comparative Examples 2 to 4, which show the results obtained by this alkali weight reduction treatment, the anti-fluffing grades obtained are the same as those in Examples 1 and 2. It was a good result of grade 5, but the result of the strength test dropped to 50% or less of that of Example 1, and a significant deterioration in the strength of the cloth was observed. Therefore, it is difficult to maintain the original strength and feel of the cloth used as the raw material. Furthermore, the anti-fluffing countermeasures by weight reduction processing tend to vary in texture or strength due to the difference in weight reduction rate, so they are not suitable anti-fluffing countermeasures from the viewpoint of stable anti-fluffing countermeasures. Countermeasures. In Comparative Example 6, the anti-pilling grade was 3.5 grades. Compared with Comparative Example 7, the anti-pilling property was improved, but because there were a large number of molten balls produced by singeing on the surface of the cloth, the feel of the cloth deteriorated. Will damage the value of the product. Industrial availability

The anti-pilling fabric of the present invention has excellent fuzz resistance, good hand feeling, and no obvious decrease in strength, so it is suitable for use in various clothing or other fiber products with desired hand feel or appearance, and it has been difficult to be practical until now. It is a braided fabric spun by a synthetic fiber machine.

1‧‧‧Reverse Roller 2‧‧‧Reverse Roller 3‧‧‧Heat Cylinder 4‧‧‧Heat Cylinder 5‧‧‧Heat Cylinder 6‧‧‧Reverse Roller 7‧‧‧Reverse Roller 8‧‧‧Reverse Roller 9‧ ‧‧Moveable pressure valve 10‧‧‧Abrasive belt 11‧‧‧Paper deduster 12‧‧‧Blank deduster 13‧‧Reverse roller 14‧‧‧Bill deduster 15‧‧‧Reverse roller 16‧ ‧‧Guide roller 17‧‧‧Guide roller 18‧‧‧Reverse roller 19‧‧‧Shaking device

Fig. 1 is the electron micrograph of the cloth surface of the finished product (conventional processed product) of the staple fiber polyester plain weave fabric produced in Comparative Example 1 after washing 10 times. Fig. 2 is the electron micrograph of the cloth surface of the finished product (conventional processed product) of the staple fiber polyester plain weave fabric produced in Comparative Example 1 after washing 30 times. Fig. 3 is the electron micrograph of the cloth surface of the finished product (singeing+polishing) of the staple fiber polyester plain weave fabric produced in embodiment 1 after washing 10 times. Fig. 4 is the electron micrograph of the cloth surface of the finished product (singeing+polishing) of the staple fiber polyester plain weave fabric manufactured in embodiment 1 after washing 30 times. Fig. 5 is the staple fiber polyester plain weave fabric manufactured in embodiment 1, when the gray cloth in its manufacturing process just finished singeing after desizing and scouring, the electron micrograph of the cloth surface (only singeing). Fig. 6 is the finished product (singeing+polishing) of the short-fiber polyester plain weave fabric manufactured in Example 1, and its cloth surface is an electron micrograph when it is just completed. Fig. 7 is the finished product (conventional processed product) of the staple fiber nylon plain weave fabric of comparative example 3, the electron micrograph of its cloth surface (conventional processed product). Fig. 8 is the finished product (singeing+polishing) of the staple fiber nylon plain weave fabric of embodiment 2, and its cloth surface is the electron micrograph when just finishing. Fig. 9 is the short-fiber nylon plain weave fabric of embodiment 2, when the gray cloth in its manufacturing process has just finished singeing after desizing and scouring, the electron micrograph of the cloth surface (only singeing). Fig. 10 is a schematic diagram showing an example of a belt sand mill device for forming polishing marks by polishing molten balls at the tips of hairs after singeing and rubbing them together.

Claims (8)

An anti-pilling fabric, comprising only short fibers of thermoplastic synthetic fibers obtained by cutting fibers that have been made into filament yarns, or a blended yarn composed of short fibers of thermoplastic synthetic fibers and other natural fibers, characterized in that: The surface of at least one side of the cloth has the melting ball at the end of the short fiber and the polishing marks of the melting ball at the tip of the hairiness of the short fiber; and the anti-fluffing cloth is produced by a method comprising the following steps: A type sand mill is used for polishing, and the molten ball at the tip of the short fiber hairiness formed on the one-side surface of the cloth is scraped to form polishing marks. Such as the anti-pilling fabric of claim 1, wherein the aforementioned thermoplastic synthetic fibers are selected from polyesters, polyamides, polyacrylics, polyvinyl chlorides, polyvinylidene chlorides, polyvinyl alcohols, Fibers in the group consisting of polyolefins and polyurethanes. The anti-pilling fabric of claim 1 or 2 is a knitted fabric. For the anti-pilling fabric of claim 3, it follows the JIS L 1930 C4M method, that is, after washing 10 times and 30 times with a drum, it follows the JIS L 1076 A method, that is, the anti-fluffing method measured by the ICI type testing machine All grades are 3 or above. A method of manufacturing an anti-fluffing fabric according to claim 1, comprising the following steps: using a machine-spun yarn as a raw yarn to weave or knit a fabric with hairiness of short fibers, the machine-spun yarn comprising thermoplastic synthetic fiber short fibers, or blended yarns composed of short fibers of thermoplastic synthetic fibers and other natural fibers; the step of singeing at least one side surface of the obtained fabric to form molten balls at the ends of the short fibers; Polishing is a step in which the molten balls formed on the tip of the hairiness of the short fibers formed on the surface of one side of the obtained cloth are rubbed to form polishing marks. Such as the manufacturing method of the anti-pilling fabric of claim 5, wherein the aforementioned thermoplastic synthetic fibers are selected from polyesters, polyamides, polyacrylics, polyvinyl chlorides, polyvinylidene chlorides, polyethylene Fibers in the group consisting of alcohols, polyolefins, and polyurethanes. The method of manufacturing an anti-pilling fabric according to claim 5 or 6, wherein the aforementioned anti-fluffing fabric is a knitted fabric. Such as the manufacturing method of the anti-pilling fabric of claim 7, wherein the aforementioned anti-fluffing fabric follows the JIS L 1930 C4M method, that is, after washing 10 times and 30 times with a drum, follows the JIS L 1076 A method, that is, uses ICI type The anti-pilling grades measured by the testing machine method are all above grade 3.

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